Waterco Turbotemp 200HD, Installation And Operation Manual

Page 1: ...ight any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department 240 VAC NATURAL GAS LP GAS MODELS Natural Propane 200HD 200 MJ h 270201 270202 300HD 300 MJ h 270301 270302 400HD 400 MJ h 270401 270402 FOR YOUR S...

Page 2: ...ting Single Wall Stainless 25 Steel Vent to the Heater Horizontal or Vertical Venting Flexible 28 Duct Flex Vent Corrosive Vapors and Possible Causes 28 Control Panel Indexing 29 Final Installation Check 29 Electrical Connections 29 Fireman s Switch Connection 30 Remote Control Connections Turbotemp Wiring Diagram 32 Electrical Schematic Ladder Diagram Section 4 Operation 34 Basic System Operation...

Page 3: ...Mega Joule MJ hr 3 Construction HD Heavy Duty Model 4 Fuel Type LP Propane gas or N Natural gas MT 300 HD N H I N HEATER IDENTIFICATION NUMBER ID DESIGNATOR FOR WATERCO WATER POOL SPA TURBOTEMP HEATERS Example 1 2 3 4 MT TURBOTEMP HD HEAVY DUTY MODEL FUEL TYPE N NATURAL GAS LP PROPANE GAS MODEL SIZE MJ INPUT Mega Joule MJ HR 200 200 MJ HR 300 300 MJ HR or 400 400 MJ HR HEATER DATA RATING PLATE The...

Page 4: ... The information in this manual applies to all Turbotemp models READ AND REVIEW THIS MANUAL COMPLETELY it is very important that the owner installer read and understand the section covering installation instructions and recognize the local and state codes before installing the Turbotemp Its use will reduce service calls and chance of injury and will lengthen product life History and experience has...

Page 5: ...e water heaters The manufacturer s warranty may be void if for any reason the heater is improperly installed and or operated Be sure to follow the instructions set forth in this manual OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 20 C WILL CAUSE HARMFUL CONDENSATION AND WILL DAMAGE THE HEATER AND VOID THE WARRANTY Do not use the heater to protect pools or spas from freezing if the...

Page 6: ...er temperatures should never exceed 40 C A temperature of 37 C is considered safe for a healthy adult Special caution is suggested for young children Prolonged immersion in hot water can induce hyperthermia 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant women beware Soakin...

Page 7: ... IMMEDIATELY TURN OFF THE POOL HEATER LEAVE THE VICINITY OF THE POOL OR SPA AND GET INTO FRESH AIR IMMEDIATELY THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE RESUMING OPERATION EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR DEATH Install this pool heater far from open windows doors vents and other openings see page 16 for minimum distances Waterco strongly rec...

Page 8: ... Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or other volatile flammable liquids near heater Risk of explosion if unit is installed near propane gas storage Propane LP gas is heavier than air Consult local codes and fire protection authorities about specific installation requirements and restrictions Locate the heater away from propane gas...

Page 9: ...ccess door panels must be in place to provide proper ventilation Do not operate the heater for more than five 5 minutes with the access door panels removed This heater is design certified by IAPMO as complying with the Standard for Gas Fired Pool Heaters and is intended for use in heating fresh water swimming pools or spas The heater is designed for the heating of chlorine bromine or salt system s...

Page 10: ... replaced immediately HEATER DESCRIPTION Figure 1 is a diagram of the heater showing how it operates Precisely matched orifice plates meter the air and gas into the mixer The blower draws the air and gas through the mixer and forces it into the burner s flame holder A sealed heat exchanger surrounds the flame holder discharging exhaust gases out the flue Five 5 cm PVC water piping connects directl...

Page 11: ...AFS senses the pressure drop across the air metering orifice As soon as there is sufficient air flow the AFS closes closing the circuit to the hot surface igniter HSI which ignites the fuel mixture On a call for heat the blower and HSI are energized In about 20 seconds the gas valve opens and ignition occurs The HSI then switches to a sensing mode and monitors the flame The heater is equipped with...

Page 12: ...ire installation and repair by licensed personnel If this applies in your state be sure your contractor bears the appropriate license See Figure 2 for Outdoor Installations DIMENSIONS IN CENTIMETERS INCHES 53 3 cm 21 0 82 8 cm 32 61 58 5 cm 23 02 71 5 cm 28 15 40 6 cm 16 TOP FRONT EXHAUST SIDE PLUMBING SIDE 25 7 cm 10 13 14 2 cm 5 6 ELECTRICAL CONDUIT PORT 71 6 cm 28 2 57 7 cm 22 7 40 6 cm 16 0 Fi...

Page 13: ...e pool by putting chlorine tablets or sticks into the skimmer s When the pump is off this will cause a high concentration of chlorine to enter the heater which could cause corrosion damage to the heat exchanger Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater filters or pump When chemical feeders are installed in the circulation of the pi...

Page 14: ...stalling heater Connect the heater directly to 5 cm PVC pipe using the integral unions provided Heat sinks are not required The low thermal mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down unexpectedly Occasionally a two speed pump will not develop enough pressure on the low speed to operate the heater In this case run the pump at high s...

Page 15: ...eater failure The gas meter should be checked to make sure that it will supply enough gas to the heater and any other appliances that may be used on the same meter Insufficient gas supply will cause the heater to operate below its designed performance or not at all The gas line from the meter will usually be of a larger size than the gas valve supplied with the heater Therefore a reduction of the ...

Page 16: ...ns must be leak tested Do NOT use an open flame to test for leaks Test all gas connections for leaks with soapy water The gas valve must be completely disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 6 0 kPa 87 psig TESTING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE Risk of fire and explosion Alteration service...

Page 17: ...isonous gas you cannot see or smell Symptoms of carbon monoxide exposure or poisoning include dizziness headache nausea weakness sleepiness muscular twitching vomiting and inability to think clearly IF YOU EXPERIENCE ANY OF THE ABOVE SYMPTOMS IMMEDIATELY TURN OFF THE POOL HEATER LEAVE THE VICINITY OF THE POOL OR SPA AND GET INTO FRESH AIR IMMEDIATELY THE POOL HEATER MUST BE THOROUGHLY TESTED BY A ...

Page 18: ... N 460738 see Figure 9 IMPORTANT In an outdoor installation it is important to ensure water is diverted from overhanging eves with a proper gutter drainage system The heater must be set on a level foundation for proper drainage This unit shall not be operated outdoors at temperatures below 7 C HEATER CLEARANCES OUTDOOR If the heater is located under a roof or deck overhang there must be at least 1...

Page 19: ...he heater installation Combustion air can be contaminated by corrosive chemical fumes which can damage the heater and will void the warranty WARNING If you are considering connecting this heater to a pre existing vent system make sure that the vent system meets the appropriate venting requirements as given in this manual on pages 17 28 If not replace the vent system DO NOT use a draft hood with th...

Page 20: ... panel On an outdoor shelter installation the exhaust discharges into a vent pipe Orient the heater so that the vent pipe does not interfere with adjustment of the operating controls The control panel located on the top panel can be rotated to any of the three sides of the heater for easy access However the control panel must not be located on the side where the vent is located OUTSIDE VENT COVER ...

Page 21: ...ay apply These openings shall directly or through duct connect to outdoor air Waterco Limited does not recommend indoor installations that do not provide combustion air from outside the building Air Supply Requirement Guide for Turbotemp Heaters Minimum Net Free Open Area for Each Opening Square Inches Centimeters Model All Air From Inside Building All Air From Outside Building Combustion Vent Com...

Page 22: ...R FLUE EXHAUST VENT FLUE EXHAUST VENT TEMPERATURES CAN BE IN EXCESS OF 400 F FLUE EXHAUST VENT MUST BE CATEGORY I or CATEGORY III METAL VENT WARNING Combustion 3 in PVC Pipe Inlet Air Intake Duct Requirements Combustion Air Intake 3 in Pipe Vertical or Horizontal No of 90 Elbows Maximum Length in Feet M 0 70 ft 21 3 M 1 58 ft 17 7 M 2 46 ft 14 0 M 3 34 ft 10 4 M 4 22 ft 6 7 M ...

Page 23: ...al finishing and processing plants Refrigerants acids glues and cements construction adhesives Dry cleaning and laundry areas Bleaches detergents or laundry soaps containing chlorine Waxes and cleaners containing chlorine calcium or sodium chloride Table 5 Chemicals should not be stored near the heater installation Combustion air can be contaminated by corrosive chemical fumes which can void the w...

Page 24: ...ith AS NZS 5601 1 and local codes Double wall vent connector is recommended however single wall pipe is allowed in some circumstances Consult your local code official for detailed information Do not use a draft hood with this heater To connect a double wall metal gas vent to the heater order the appropriate Metal Flue Collar from the chart below 1 See Table 6 to determine allowable vent sizes for ...

Page 25: ... 4 ft 10m 32 8 ft 1 16m 52 5 ft 5 33m 17 5 ft 10 67m 35 ft 17m 55 8 ft 5 67m 18 6 ft 11 33m 37 2 ft 18m 59 ft 6m 19 7 ft 12m 39 4 ft 19m 62 3 ft 6 33m 20 8 ft 12 67m 41 6 ft 20m 65 6 ft 6 67m 21 9 ft 13 33m 43 7 ft 21m 68 9 ft 7m 23 ft 14m 45 9 ft 22m 72 2 ft 7 33m 24 ft 14 67m 48 1 ft Table 6 Permitted Minimum and Maximum Vent Heights By Size and Heater Model Double Wall Vent with Double Wall Con...

Page 26: ...T interchangeable Mixing parts from more than one manufacturer may cause leaks or damage to vent When assembling a vent pick one manufacturer and be sure that all vent parts come from that manufacturer and are specified by the manufacturer for your system Follow manufacturer s instructions local code requirements and AS NZS 5601 1 standards carefully during assembly and installation WARNING 4 Inst...

Page 27: ... local codes Do not use a draft hood with this heater Install the vent according to the vent manufacturer s detailed instructions Note Keep a 150 cm 6 in minimum clearance between the vent pipe and combustible surfaces Follow the vent manufacturer s instructions and code requirements Do not place any insulating materials around the vent or inside the required clear air space surrounding the vent S...

Page 28: ...appliance adapter kits call our Customer Service dept Part No 6844320 150mm Flexible Duct Exhaust Double Wall Metal 2 Remove the outside vent cover 3 Install the Appliance Adapter in the Vent Body of the heater located under the outside Vent Cover Before connecting the Appliance Adapter to the Vent Body wet a clean cloth or paper towel with isopropyl alcohol rubbing alcohol and vigorously wipe the...

Page 29: ... Do not fill the space around the vent that is the clear air space in the thimble or firestop with insulation The roof opening must be located so that the vent is vertical 6 Vent Termination Vertical See Figures 14 15 and 16 for height of vent termination above the roof Use an Approved vent terminal specified by local and national codes and your manufacturer s instructions A roof termination must ...

Page 30: ...1 2 M 4 ft horizontally from electric meters gas meters regulators and relief equipment at least 2 1 M 7 ft above grade adjacent to walkways or similar traffic areas Allow at least 1 M 3 ft vertical clearance over vent termination when terminating under an overhang or deck Avoid corners or alcoves where snow or wind could have an effect Exhaust may affect shrubbery and some building materials Keep...

Page 31: ...l venting See Table 8 for maximum permissible Flexible Vent lengths NOTE After installation installer must check for correct and safe operation of the heater NOTE KEEP A 150 CM 6 IN MINIMUM CLEARANCE BETWEEN THE VENT PIPE AND COMBUSTIBLE SURFACES FOLLOW THE VENT MANUFACTURER S INSTRUCTIONS AND CODE REQUIREMENTS Each 90 bend reduces the maximum horizontal vent run by 3 6 m 12 feet and each 45 bend ...

Page 32: ...HECK After installation the installer MUST test and check that the heater is operating and functioning properly Some building codes require that the heater be anchored to the equipment pad or platform to withstand high wind pressures created during hurricanes A Bolt Down Bracket Kit P N 460738 is available with anchor clamps designed to hold the unit to the equipment pad in high wind conditions se...

Page 33: ...se 5 The filter pump should run continuously when the heater is on and for at least 15 minutes after the heater turns off Any switches in the pump circuit including circuit breakers that can disconnect the pump must also disconnect the heater 6 Do not wire single pole switches including protective devices into a grounded line The heater is not sensitive to polarity Use the provided waterproof wire...

Page 34: ... 4b To connect a 3 Wire Control Connect wires between the control board terminals on the heater and the external relays as shown in Figure 25 on page 32 Use at least 2 relays per heater to allow for an OFF setting on each heater mode Select relays that can handle logic level switching DO NOT apply line voltage to control board terminals Move jumper as shown in Figure 25 on page 28 to enable extern...

Page 35: ...ne Pool Line IGNITION CONTROL MODULE DIAGNOSTIC INDICATOR F1 F2 24 VAC S1 240 S1 120 L1 L1 L2 BM FL F1 L2 S2 TH IND VALGND GND GND BLOWER Line 2 120 VAC IGNITER TRANS Line 1 Ground JUNCTION BOX F I R E M A N S S W I T C H Replace jumper with leads to Fireman s Switch field installed 24VAC SEC Y W Y W Y R Y O Y BL O W W BK BK O GY GY BK BK R Y BK W BL Y BK W BL GY GY GY GY BK BK W R R W G Y Y R R Y...

Page 36: ...ITCH HI LIMIT SWITCH WATER PRESSURE SWITCH COM NO AGS SWITCH VAL GAS VALVE THERMISTOR SENSOR STACK FLUE SENSOR NOTES 1 AND TH L1 L2 F1 F2 S1 24 VAC S2 GND IND VAL ARE CONNECTED ON THE IGNITION MODULE 2 3 PIN AND SOCKET CONNECTOR IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED THEY MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT LADDER DIAGRAM INLET TEMPERATURE CONTR...

Page 37: ...h an ignition device which automatically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building I...

Page 38: ... to clear out any gas If you then smell gas STOP Follow B in the Before Start up instructions page 34 If you don t smell gas go to the next step 7 Turn on the outside external manual shut off gas valve see Figure 27 8 Set 3 way valves on inlet and outlet to pool or spa as appropriate 9 Turn on all electric power to the appliance 10 Press either the POOL ON or SPA ON button switch on the operating ...

Page 39: ...ater Pressure Switch or render it inoperable WARNING Figure 28 Figure 29 Air Flow Switch The water pressure switch see Figure 29 If the water flow is restricted the water pressure switch may prevent the burner from firing and cause the Service System light to go on If the light remains on after the filter has been serviced have a qualified service technician check the system For deck level heater ...

Page 40: ...in the High Limit Device The Turbotemp series of heaters contains two 2 high limit devices which are located on the main inlet outlet header Figure 30 OPERATION OF IGNITION MODULE The Ignition Module see Figure 31 is microprocessor based and operates on 24VAC supplied by the transformer The control utilizes a microprocessor to continually and safely monitor analyze and control the proper operation...

Page 41: ...ill indicate the temperature setting After five seconds the display will return to the actual pool spa temperature In addition to the digital temperature display there are five indicator lights The POOL ON light indicates that the pool water temperature is governing operation of the heater The SPA ON light indicates that the spa water temperature is governing operation of the heater The HEATING li...

Page 42: ...ximum spa temperature to 40 C 104 F or less E Wait up to 30 seconds the SPA ON light will turn off and the unit will shut down To override the time delay push the Max Temp Set Point button again 4 Reinstall the access door panels TEMPERATURE SETTING The heater comes factory set at 25 6 C 78 F for the pool mode and 37 8 C 100 F for the spa mode Using the up and down arrows you can set the pool spa ...

Page 43: ...an shock burn or kill Disconnect power before servicing any components Go to chart HEATER WILL NOT FIRE A Page 41 Go to chart HEATER WILL NOT FIRE B Page 42 Go to specific safety switch troubleshooting chart Pages 45 and 46 Go to chart HEATER WILL NOT FIRE C Page 43 Are any red diagnostic LED s on back of board AGS AFS SFS HLS PS or THERMISTOR on NO NO NO NO NO YES YES YES NO YES YES Does red SERV...

Page 44: ...Check for 24 VAC at secondary of Transformer Check for Line Voltage at Transformer primary pins White connects to Pin 3 on Transformer Black to Pin 2 Orange to Pin 1 240V check Pin1 to Pin 3 Jumper Fireman s Switch at Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on Leaving jumper in place check for 24 VAC between Fireman s Switch terminals and ground J...

Page 45: ... Verify that pump is on filter is not blocked and the water flow is above the minimum requirement Check that water pressure is within the adjustment range of the Pressure Switch 0 35 kPa Verify that switch wiring is OK and Pressure Switch port is not blocked and replace water Pressure Switch Check whether any of the red diagnostic LED s on back of board AGS AFS SFS HLS or PS are on GO TO HEATER WI...

Page 46: ...r heat SEE NOTE 2 Turn off power to heater for 5 seconds and turn back on Make sure temperature setting is above water temperature Wait one minute Does heater fire and stay on Did Blower come on Verify that gas is flowing to burner during ignition try Observe gas meter for movement during ignition try wait for about 30 seconds after calling for heat Check for 24 VAC between TH and GND terminals on...

Page 47: ...place meter or All of the above YES IMPORTANT READ ME FIRST If your heater is correctly connected to 240 Volts AC the Ignition Control Module ICM will convert the 240VAC to an intermittent pulse to the ignitor Digital meters don t read this type of signal well An analog meter will give a better reading than a digital meter If the ICM is bad your voltmeter will read either 0 VAC or 240 VAC If your ...

Page 48: ...place Blower Replace Blower Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board YES YES NO NO NO YES YES NO AFS on Does Blower operate THERMISTOR on Verify Thermistor wiring If OK replace Thermistor Disconnect Blower and check for line voltage between pins 1 and 3 of Blower Connector on ignition try Connect cor...

Page 49: ...rcuit 0 shorted Does sensor check OK Clean tighten pins as needed Reset power to Heater and retry Heater should fire NOT OK NO NO NO NO NO SFS on Replace Stack Flue Sensor Correct Fuel Supply reset Heater and retry Heater should fire correctly Repeat checks on fuel supply Thermal Regulator check for correct orifices etc DONE DONE YES YES YES YES NO NO YES NO OK YES Replace Heater Control Board Rep...

Page 50: ...mbustion appears normal but flame does not stay lit Flame current is not being sensed Check for wet or damaged igniter with low resistance to ground Replacewith new igniter Verify burner flameholder is properly grounded Replace Ignition Control Module SYMPTOM CAUSE REMEDY Boiling in heat exchanger May be accompanied by bumping sounds Low water flow to heater Heat exchanger plugged Bypass valve stu...

Page 51: ...justment by the user Call a qualified service technician if you suspect that the burner may require maintenance DE LIMING THE HEATER Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or other volatile flammable liquids near heater or in the same room with heater WARNING Working with muriatic acid can be dangerous When cleaning elements always we...

Page 52: ...he pool to a comfortable temperature within about one day PRESSURE RELIEF VALVE Local codes may require installation of a pressure relief valve PRV Purchase separately and install a 19 mm pressure relief valve complying with the local Plumbing Codes having a capacity equal to the Mega Joule MJ hr rating of the heater The relief pressure of the valve MUST NOT EXCEED 344 kPa The relief valve must be...

Page 53: ...nstall a drain cock in the outlet pipe to drain the manifold 6 Cover air inlet grate with a plastic bag to prevent bugs leaves etc from getting into the heater NOTICE Water trapped in the heater can cause freeze damage Allowing the heater to freeze voids the warranty To return the heater to service after winterizing 1 Close drain cock and fittings 2 Before starting the heater circulate water throu...

Page 54: ...cause problems with your pool heater are improper pH disinfectant residual and total alkalinity These items if not kept properly balanced can shorten the life of the heater and cause permanent damage MAINTAINING POOL TEMPERATURE To maintain pool temperature make sure that the heater switch and valving are reset to pool settings after using the spa ENERGY SAVING TIPS 1 Keep the pool or spa covered ...

Page 55: ...H refers to the acid alkaline balance of water expressed on a numerical scale from 0 to 14 A test kit for measuring pH balance of your pool water is available from your local pool supply store see Table 10 Muriatic Acid has a pH of about 0 Pure water is 7 neutral Weak Lye solution have a pH of 13 14 RULE 7 4 to 7 6 is a desirable pH range It is essential to maintain correct pH see Table 10 If pH b...

Page 56: ... to perform with a reliable test kit You will need to test about once a week and make proper adjustments until alkalinity is in the proper range Then test only once every month or so to be sure it is being maintained See your local pool dealer for help in properly balancing the water chemistry Disinfectant levels Minimum Ideal Maximum Free Chlorine ppm 1 0 2 0 4 0 5 0 Combined Chlorine ppm None No...

Page 57: ...al System parts breakdown Key Nos 1 through 4 see Page 44 For complete Burner System parts breakdown Key Nos 5 through 7 see Page 42 For complete Water System parts breakdown Key Nos 8 through 9 see Page 43 1 2 3 5 6 4 8 9 7 Repair Parts are available from your Waterco Limited If your dealer cannot supply you Call Customer Support TURBOTEMP REPLACEMENT PARTS ...

Page 58: ...ed between 1 12 2009 and 10 31 2013 clamp lid tub design Note Kits also include Clamp Assembly O Ring and Silicon Tube see page 49 Combustion Chamber Gasket Lid Nut Washer 9x CLAMP LID TUB DESIGN TURBOTEMP REPLACEMENT PARTS ...

Page 59: ...orator Plate 15 One Piece Metal Chamber Combustion Chamber Assembly 474095 474095 474095 Insulation Kit Includes Key Nos 13 14 16 17 18 and 19 77707 0008 77707 0008 77707 0008 16 Bottom Outer Insulation Blanket 17 25 4 mm Bottom Inner Insulation 18 25 4 mm Top Insulation 19 Top Outer Insulation Blanket Lower Enclosure Insulation 42001 0074S 42001 0074S 42001 0074S 20 One Piece Metal Elbow Combusti...

Page 60: ...9 Water Pressure Switch 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16 18 x 2 3 4 Hex Cap Screw 10 13 Connector Tube O Ring 2 14 Connector Tube Kit Includes 1 Connector Tube and 1 O Ring 2 77707 0017 77707 0017 77707 0017 15 Thermal Regulator Kit Incl Key Nos 16 17 18 19 and Spring Clip 77707 0010 77707 0010 77707 0010 16 Thermal Regulator Includes Spring Clip 3800...

Page 61: ...rd 1 42001 0056S 42001 0056S 42001 0056S 9 Fireman s Switch Fuse 31 75mm X 6 35 mm 1 32850 0099 32850 0099 32850 0099 10 Fenwal Ignition Control Module 1 474103Z 474103Z 474103Z 11 Transformer 120 240V 1 42001 0107S 42001 0107S 42001 0107S 12 Air Flow Switch 1 42001 0061S 42001 0061S 42001 0061S 13 Control Board Kit NA LP Series 1 42002 0007S 42002 0007S 42002 0007S Heater Wiring Harness 1 474163Z...

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